Prediction refractory property measurement system

Abstract

A measurement system is provided for predicting the future state of a refractory lining that lines the inner surface of an outer wall of a production vessel and is exposed to an operating cycle while being exposed to a high-temperature environment for producing nonmetals and the produced nonmetals. The system includes one or more laser scanners and a processor. The laser scanner is configured to perform one or more pre-operation laser scans of the refractory lining before the operating cycle to collect data regarding its structural condition before the operating cycle, and to perform one or more post-operation laser scans of the refractory lining after the operating cycle to collect data regarding its structural condition after the operating cycle. The processor is configured to predict the future state of the refractory lining after a subsequent operating cycle based on the calculated exposure impact of the operating cycle.

Description

Technical Field

[0001] The present invention relates generally to refractory analysis, and more specifically to systems and methods for predicting refractory performance.

Background Art

[0002] Industrial processes, such as steel manufacturing and other processes involving high-temperature erosive environments within manufacturing vessels, are supported by the collection of increasing amounts of process data and parameters. For the purpose of optimizing processes and improving efficiency, many statistical, analytical, and data manipulation solutions are available for quickly and efficiently analyzing process data. A process optimization system composed of computer system hardware and software collects raw process data and associates that raw process data with process changes, modifications, and upgrades. This system can timestamp and associate the various collected data. In advanced formats, the system can also take analytical and statistical correlations of multiple interdependent parameters. By using these correlations, the system can evaluate the impact on process efficiency. Many of the collected process parameters directly affect the performance of the refractory lining, either individually or in correlation.

[0003] A system as described above is used in the process of manufacturing molten steel in primary melting apparatuses such as basic oxygen converters and electric arc furnaces. Also, this system can be used in processes in secondary refining and transport vessels such as steel ladles, degassing apparatuses, argon oxygen decarburization, and vacuum oxygen decarburization furnaces. Containers for containing molten steel need to use a lining made of a high-temperature refractory resistant to molten steel and molten slag. However, both molten steel and molten slag corrode the refractory lining.

[0004] Furthermore, the system as described above can be used in processes for manufacturing glass, cement, lime, or other minerals, and in other high-temperature units such as incinerators. Additionally, the system can also be used in the production and purification of oil, gas, chemicals, or the like. Containers utilized in processes operating at high temperatures, for example, continuous and batch glass melting furnaces, rotary kilns and smelting furnaces for cement or lime, and rotary kilns and smelting furnaces for processing other minerals, or preheating towers and coolers, or various petrochemical reformers such as primary and secondary ammonia reformers, or fluid catalytic cracking units, or thermal reactors such as sulfur recovery units, or gasifiers, fluidized beds, incinerators, etc., must include a lining made of a high-temperature refractory material that is resistant to corrosive and erosive conditions, or non-metallic liquids, or molten slag and coatings. However, all of the above conditions will corrode the refractory lining.

[0005] The level and progression of corrosion of the refractory lining have conventionally been measured by three widely accepted and still employed methods, namely visual observation, infrared mapping, and laser scanning. Visual observation of refractory lining corrosion can be carried out during the maintenance of the refractory lining. Also, after the end of the service life of the refractory lining, visual observation of the corrosion of the refractory lining can be performed by physically measuring the remnants of the refractory lining. The level and progression of corrosion of the refractory lining of a glass melting furnace can also be measured by radar detection.

[0006] Infrared mapping of refractory lining corrosion is performed on the outer surface of a lined container containing molten steel, glass, cement, lime, oil, gas, chemicals, or other minerals or materials at specific steps or times when each of the molten steel, glass, cement, lime, oil, gas, chemicals, or other minerals or materials is in contact with the container. The purpose of infrared mapping of refractory lining corrosion is to correlate the temperature of the outer surface of the container containing the contents with the condition of the refractory lining attached to the container. The infrared mapping may be as simple as visually inspecting the infrared mapping image. Visual inspection of the infrared mapping image can be further complemented by software operations, advanced temperature images, and data reports.

[0007] Laser scanning of refractory lining corrosion is performed on the inner surface of a container with a lining, which may be empty or, in some cases, completely or partially filled, at a specific process location. In a laser scanning system, multiple types of hardware and devices, including but not limited to a laser time-of-flight camera, can be utilized. Software packages that can process point cloud data into a fully geometrically described image and generate various data reports can be used to analyze the data collected from the laser scan. The purpose of this method is to measure the actual shape, remaining thickness, or other detailed parameters of the refractory lining within an accuracy of 2 mm. For molten steel, such parameters may include the condition of functional parts of the ladle, such as well blocks and tapping spouts, or the polishing efficiency of well blocks and tapping spouts, or the measurement of the amount of steel trapped in the depressions at the bottom of the ladle, or the condition of the passageways of flow control parts, which may include but are not limited to slide gates. For glass, cement, lime, oil, gas, chemicals, or other minerals or materials, such parameters may include the condition of the functional parts of each container in contact with them, such as inlet ports, outlet ports, crowns, ceilings, or specific functional parts, but are not limited to these.

[0008] Based on the response of radar waves during the operation of a glass melting furnace, by determining whether the radar waves enter regions with different densities, radar waves can be used to measure the thickness of the refractory lining in the glass melting furnace. This radar measurement is performed from the outer surface of the glass melting furnace.

[0009] Conventionally, the above four methods are used independently. Refractory lining corrosion is mainly identified by visual observation in industrial processes. However, infrared mapping, radar scanning, and laser scanning are considered alternative and independent solutions for evaluating the corrosion of refractory linings. In fact, these four methods compete in the market, but the costs vary greatly. The cost of visual observation is mainly related to various expenses. Infrared mapping systems and radar scanning systems in glass melting furnaces are less costly than laser scanning systems.

Summary of the Invention

Problems to be Solved by the Invention

[0010] However, using these methods individually may have drawbacks in certain situations. For example, very rarely, visual observation of refractory lining corrosion may not match the actual conditions of the refractory lining, which have been physically evaluated using laser scanning after each heating or process cycle, or to a lesser extent, infrared mapping. Furthermore, visual observation cannot collect valuable process optimization data that can be used to calculate the predicted performance of the refractory lining.

[0011] Infrared mapping of refractory lining corrosion is indirect and determines the state of the refractory lining by observing the outer surface. The temperature measurement values collected by the infrared mapping method are affected by the heat flow through the actual lining thickness. However, on the other hand, the temperature measurement values are also affected by the temperature of the molten steel, as well as the temperature impregnated in the lining voids by the molten steel, process fluids, gases, solids, or molten slag and coatings. Such impregnation is common and can cause errors in the measurement values obtained by infrared mapping, leading to premature replacement of the refractory lining and increased costs.

[0012] Laser scanning of refractory lining corrosion is direct and measures the actual state and thickness of the refractory lining with high precision. However, laser scanning cannot measure the thickness and state of the refractory lining when the refractory lining is covered by slag or coating during measurement. That is, if accurate results are desired from laser scanning, it is not possible to leave molten steel, other melts such as glass, molten slag, or coatings in the ladle or container. Laser scanning in such a situation can only measure the actual state and thickness of the visually exposed part of the refractory lining, such as the glass melting crown. Even if there are significant defects in the lining, such as large cracks or insufficient thickness, if they are temporarily covered by a slag coating, laser scanning will produce incorrect measurement results. Then, during operation, the coating may melt out, exposing the hidden defects of the refractory lining to the high-temperature process environment containing molten steel and non-metals. This can lead to major damage to the refractory lining.

[0013] Furthermore, radar scans in glass applications have an accuracy within 5 mm, which is lower than the high accuracy achievable by laser scans. Additionally, in radar scans, each point needs to be measured individually. Thus, radar scans are time-consuming. The number of points that can be completed through an overall scan of a container is usually limited to not exceeding 150 points. Similar to infrared cameras, radar scans cannot distinguish between glass melt or glass infiltrates, and may produce incorrect measurement values when such infiltrates are behind the refractory lining.

[0014] The present invention was developed to address these and other problems by providing a system that can identify refractory lining corrosion using both laser scans and infrared mapping, and in the case of a glass melting furnace, optionally by radar scans. Furthermore, the present invention provides a system that can predict the future performance of the problematic refractory lining using process characteristics and variables in addition to the data obtained by laser scans, infrared mapping, and radar scans.

Means for Solving the Problems

[0015] According to one embodiment of the present invention, there is provided a measurement system for predicting the future state of a refractory lining that is lined on the inner surface of the outer wall of a production vessel and is exposed to an operating cycle while being exposed to a high-temperature environment for producing a non-metal and the produced non-metal. This system includes one or more laser scanners and a processor. The laser scanner is configured to perform one or more pre-operation laser scans of the refractory lining before the operating cycle to collect data on the structural conditions before the operating cycle, and after the operating cycle, to perform one or more post-operation laser scans of the refractory lining to collect data on the structural conditions after the operating cycle. The processor is configured to calculate the exposure effect of the operating cycle on the refractory lining by comparing the collected pre-operation structural condition data with the collected post-operation structural condition data, and based on the calculated exposure effect of the operating cycle, to predict the future state of the refractory lining after one or more subsequent operating cycles.

[0016] According to another embodiment of the present invention, there is provided a method for predicting the future state of a refractory lining that is lined on the inner surface of the outer wall of a production vessel and is exposed to an operating cycle while being exposed to a high-temperature environment for producing a non-metal and the produced non-metal. This method includes, before the operating cycle, performing one or more pre-operation laser scans of the refractory lining before heating to collect data on the structural conditions before the operating cycle, and after the operating cycle, performing one or more post-operation laser scans of the refractory lining to collect data on the structural conditions of the refractory lining after the operating cycle, and calculating the exposure effect of the operating cycle on the refractory lining by comparing the collected pre-operation structural condition data with the collected post-operation structural condition data by a processor, and predicting, by the processor, the future state of the refractory lining after one or more subsequent operating cycles based on the calculated exposure effect of the operating cycle.

Advantages of the Invention

[0017] These and other advantages will become apparent from the following description of the preferred embodiments, along with the accompanying drawings and the claims.

Brief Description of the Drawings

[0018] The present invention can take a physical form with respect to specific components and their arrangements, and its preferred embodiments are described in detail in the specification and illustrated as follows in the accompanying drawings, which form a part of this specification.

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Modes for Carrying Out the Invention

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[0025] The following detailed description is provided to assist the reader in comprehensively understanding the methods, apparatuses, and / or systems described herein. However, various changes, modifications, and equivalents of the systems, apparatuses, and / or methods described herein will be apparent to those skilled in the art. Further, descriptions of functions and structures well known to those skilled in the art may be omitted for the sake of clarity and conciseness.

[0026] Throughout the drawings and the detailed description, the same reference numerals refer to the same elements. The drawings may not be to scale, and the relative sizes, ratios, and depictions of elements in the drawings may be exaggerated for clarity, illustration, and convenience.

[0027] The features described herein may be embodied in different forms and are not to be construed as limited to the examples described herein. Rather, the examples described herein are provided so that this disclosure will be thorough and complete, and will convey the full scope of the disclosure to those skilled in the art.

[0028] First, for the purposes of the description herein, a "metallurgical vessel" refers to any vessel that can be used within a process for the production or refining of molten steel. This includes, but is not limited to, primary melting devices or secondary metallurgical vessels. Primary melting devices include, but are not limited to, basic oxygen converters and electric arc furnaces. Examples of secondary metallurgical vessels include, but are not limited to, ladle metallurgy furnaces, degassing devices, argon oxygen decarburization vessels, or vacuum oxygen decarburization vessels. Examples of secondary steelmaking or metallurgical vessels tasked with transporting molten steel include the empty ladle vessel 16 and the full ladle vessel 18, which are described in more detail in the following description. However, the use of metallurgical vessels is not limited to use with molten steel and can also hold other molten metals in general, and the embodiments described herein are not limited thereto.

[0029] For the purposes of the description herein, a "manufacturing vessel" refers to any vessel that can be used within a high-temperature process for the production or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals. This includes, but is not limited to, continuous and batch glass melting furnaces, rotary kilns for cement or lime and blast furnaces, or rotary kilns and blast furnaces for processing other minerals, or preheating towers and coolers, or various petrochemical reformers such as primary and secondary ammonia reformers, or fluid catalytic cracking units, or thermal reactors such as sulfur recovery units, or gasifiers, fluidized beds, incinerators, and the like. However, the use of manufacturing vessels is not limited to use with glass, cement, lime, chemicals, oil and gas and can also hold or process other non-metals in general, and the embodiments described herein are not limited thereto.

[0030] Furthermore, if applicable, the mill operating parameters that affect the performance of the refractory lining in a metallurgical vessel are described along with their variability and measurement methods. For example, for the purposes of the description herein, "heating" may refer to one operation from the beginning to the end of the steelmaking process.

[0031] Furthermore, if applicable, describe the operating parameters that affect the performance of the refractory lining in the production vessel, along with their variability and measurement methods. For example, for the purposes of the description in this specification, an "operating cycle" may refer to one operation from the beginning to the end of the manufacturing process. Also, an "operating cycle" may refer to the time between shutdowns, the time between inspections, the time between maintenance, the time between repairs, or the time between laser scans of the production vessel, etc.

[0032] For the purposes of the description in this specification, a "scrap or charge mix" for a process for the production or refining of molten steel can include batches having specific ratios of individual scrap qualities and iron units for the steel grades to be produced, including, but not limited to, iron scrap specified by the guidelines from the Institute of Scrap Recycling Industries, and furthermore, can include, but not limited to, heavy melting steel, busheling, clipping, bundles, shredding, turning, plates, structures, cast iron, mix heavy melts, rails, railways, and can bales, and can be complemented by other iron sources of iron units, such as pig iron and hot briquette iron, which are not limited thereto.

[0033] Regarding the "scrap or charge mix" in a process for the production or refining of molten steel, there are significant variations in the quality and iron units of iron scrap available to steelmakers in their primary melting processes. The physical attributes of these materials, such as size, shape, contamination, etc., the chemical attributes of these materials, such as composition, rust, impurities, etc., and the composition of the "scrap or charge mix" for each heating directly affect the efficiency of the melting process, the period of refining metallurgy, and the corrosion and erosion of the refractories. A "scrap or charge mix" is typically a simple batch instruction with specific ratios of individual scrap qualities and iron units. These instructions are based on the availability of the charge components and the steel grades to be produced.

[0034] Furthermore, for the purposes of the description herein, a "charge mix" or "continuous feed mix" with respect to high temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals, may each include a batch or continuous feed at specific ratios of the individual raw materials and starting materials to the grade of non-metal to be manufactured.

[0035] With respect to "charge mix" or "continuous feed mix" in high temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals, there is a large variation in the quality available to non-metal manufacturers in the manufacturing process. The physical attributes of these materials, such as size, shape, contamination, the chemical attributes of these materials, such as composition, impurities, and further the composition and frequency of the "charge mix" or "continuous feed mix" for each operating cycle, directly affect the efficiency of the manufacturing process, the duration of the operating cycle, and the corrosion and erosion of refractories. A "charge mix" is typically a simple batch instruction by specific ratios of the individual inclusions and additives. A "continuous feed mix" is typically a feed instruction by specific ratios of the individual inclusions or additives. These instructions are based on the availability of the components of the charge or continuous feed mix and the grade of non-metal to be manufactured.

[0036] Furthermore, for the purposes of the description herein, "steel" and its grades may include, but are not limited to, carbon steel, nickel steel, nickel-chromium steel, molybdenum steel, chromium steel, chromium-vanadium steel, tungsten steel, nickel-chromium-molybdenum steel, and silicon-manganese steel. Further, for each grade of steel, there is a need for some variation in the processing of the steel in a primary melting device such as a basic oxygen furnace or an electric arc furnace, and in a secondary metallurgy vessel, for example, a ladle metallurgy furnace, a degassing device, an argon oxygen decarburization vessel, a vacuum oxygen decarburization vessel, or other vessels not limited thereto. These specific process requirements aimed at obtaining the required steel grades have been demonstrated to affect the performance of the refractory lining. The amount of residual carbon, the level of impurities, and the addition of alloying elements are carried out by the decarburization and deoxidation processes and have a corrosive and erosive effect specific to the refractory.

[0037] Furthermore, for the purposes of the description herein, "non-metallic" and its grades may include, but are not limited to, soda-lime-silicate containers or flat glass, or soda-silicate water glass, or borosilicate glass, or other special glasses, or various other glass compositions typically referred to as e-glass, c-glass, fiber glass, etc.

[0038] Furthermore, for example, there are many grades of cement clinker and standard specifications according to ASTM C-150 / C-150M-20. This specification lists five types. Type I is a standard product and is also called "ordinary cement". Type II has medium resistance to sulfate attack and is also called medium-heat cement. Type III is early-strength high-strength cement. Type IV is low-heat cement. Type V is sulfate-resistant cement with appropriate restrictions on its composition. Further, ASTM Cl 157 lists further modifications, for example, Type GU for general use, Type HE for high initial strength, Type MS for medium sulfate resistance, Type HS for high sulfate resistance, Type MH for medium heat of hydration, and Type LH for low heat of hydration, etc.

[0039] Similarly, the grades of refined products of oil (petroleum), gas, or other minerals and chemical substances produced in a high-temperature environment have specific corrosion and erosion effects on refractories. These specific process requirements aimed at achieving the required non-metallic grades have a demonstrated effect on refractory lining performance.

[0040] Furthermore, for the purposes of the description herein, "alloying additives" may include "deoxidizers" to a furnace or other metallurgical vessel, and examples include, but are not limited to, aluminum, silicon, ferrosilicon, calcium, magnesium, calcium carbide, and various deoxidation blends, or additives to ladle manufacturing vessels for secondary steelmaking and refining, such as carbon, manganese, vanadium, molybdenum, chromium, nickel, titanium, boron, niobium, and other similar materials known to those skilled in the art, but not limited to these.

[0041] The process of alloying steel is used to change the chemical composition of the steel and modify, adjust, or improve its properties according to specifications or applications. The purpose of the deoxidizer is to lower the concentration of oxygen in the molten steel. Additives are added in weight units during the melting and refining processes and vary based on the starting and target parameters of individual heating. The quantity and quality of these alloying additives have a significant impact not only on the quality of the steel but also on the corrosion of the refractory lining.

[0042] Furthermore, for the purposes of the description herein, "slag" related to the process for the production or refining of molten steel may include a solution of molten metal oxides and fluorides floating on top of the molten steel, and is formed by materials such as lime, dolomite lime, magnesia, etc., which are added before or during the steelmaking and refining processes and serve as the basis for slag formation, but are not limited to these. Additionally, for the purposes of the description herein, "flux additives" are added to optimize the fluidity of the operating slag and may include various blends of calcium aluminate, fluorite, silica sand, or synthetic slag.

[0043] "Slags" related to processes for the production or refining of molten steel are mainly liquid at the temperatures at which steel production and steel refining are carried out. They play a role in adsorbing non-metallic compounds generated in processes such as decarburization, deoxidation, desulfurization, and dephosphorization in the steelmaking process. The addition amounts of slag formers and fluxes vary depending on heating and can range from several pounds to several hundred pounds per ton of steel. The quantity and quality of these additives directly affect the chemical composition of the liquid slag and the corrosion of the refractory lining.

[0044] The typical chemical composition of "slag" in the molten steel refining process is specified in Table 1. An unbalanced slag chemical composition has a significant adverse effect on the life of the refractory lining. The chemical composition of the treated cold sample can be measured, for example, by an XRF unit, and X-ray fluorescence analysis technology is adopted to calculate the chemical composition. Although not described in detail below, the unit capable of measuring the chemical composition of the treated cold sample will be referred to as the slag chemical composition measuring device 3.

Table 1

[0045] Furthermore, for the purposes of the description in this specification, "coatings" related to high-temperature processes for the production or purification of glass, cement, lime, chemicals, oils and gases, or other materials typically called non-metals may include solutions or blends of non-metallic oxides and fluorides that occur under specific conditions during the operating cycle and at specific locations in the production vessel. "Coatings" adhere to the surface of the refractory at the temperatures at which the production or purification of non-metals is carried out. They may directly affect the corrosion of the refractory lining.

[0046] The temperature of the steel is defined to be in the range between 2800°F and 3200°F prior to tapping (or removal) of the steel from the primary melting furnace, i.e., the furnace vessel, or in the range between 2700°F and 3000°F during or near the end of secondary steelmaking in the ladle vessel. The temperature is typically measured by a thermoelectric thermocouple immersed in the molten metal or steel and preferably a consumable type such as the ladle thermocouple 25 having an effectiveness within a few degrees °F in Fahrenheit. The use of the ladle thermocouple 25 in the predictive refractory performance measurement system 4 and the system 4 itself will be described in further detail in the following description.

[0047] The temperature of a manufacturing vessel or operating cycle for high temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals is 2000°F to 3400°F in a glass melting furnace, 1600°F to 2700°F in a cement kiln, 600°F to 1600°F in a preheater tower, up to 2200°F in a cooler, 1200°F to 1400°F in a fluid catalytic cracker, 2400°F to 2800°F in a thermal reactor, up to 2200°F in an ammonia reformer, up to 3000°F in an incinerator, 2400°F to 3000°F in a gasifier, and 1500°F to 2200°F in a fluidized bed. Again, the temperature is typically measured by a thermoelectric thermocouple having an effectiveness within a few degrees °F in Fahrenheit.

[0048] Further, for the purposes of this description, the "history" of a metallurgical vessel refers to the period during which the same refractory lining is lined on the inner surface of the outer wall of the metallurgical vessel. The history is typically recorded through the collection of various "ladle tracking parameters" which include, but are not limited to, heating, plate changes, nozzle changes, and other events that may affect the metallurgical vessel during the steelmaking process in a manner that may affect the life of the refractory lining installed therein. More specifically, the ladle tracking parameters identify the times when the refractory lining of the metallurgical vessel is due for repair, replacement, or removal.

[0049] For example, in the case of a working refractory lining 34 newly installed in a metallurgical vessel, such as a working refractory lining, the number of heatings is zero and it has an initial chemical composition, origin, and physical design. After exposure to service, some of the components of the metallurgical vessel may require alteration or repair. Examples of such alterations include replacement of the flow control slide gate (after as few as the first or as many as about the 15th heating), replacement of the flow control upper or lower nozzles (after several to over 30 heatings), replacement of the gas purge cone, replacement of the well block and pocket block (from 15 heatings to the life of the ladle), replacement of the slag line (from 15 heatings to the life of the apparatus), but are not limited to these.

[0050] Furthermore, for the purposes of this description, the "history" of a production vessel for high temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals, refers to the period during which the same refractory lining lines the inner surface of the outer wall of the production vessel. This history is typically recorded through the collection of various "process tracking parameters", which include the number of operating cycles, the number of inspections, the number of preventive or emergency maintenance stops, and other events that can affect the production vessel during the non-metal manufacturing process in a way that can affect the life of the refractory lining installed therein, but are not limited to these. More specifically, the production vessel tracking parameters identify when the refractory lining of the production vessel is due for repair, alteration, or replacement.

[0051] There are possible additional repairs for metallurgical vessels, such as, but not limited to, a monolithic patch on the bottom of a ladle vessel, repair of the ladle vessel lip ring, etc. The ladle vessel at final disassembly may have the working refractory lining 34 exposed to heating at least several times, and in many cases, more than 200 times. The ladle tracking parameters are variable and have a significant impact on the overall performance of the refractory lining. Repairs or modifications to a metallurgical vessel typically require taking the vessel out of service, which in turn can cause thermal shock or thermal gradient damage to the refractory lining placed therein.

[0052] Additional repairs are also possible for manufacturing vessels used in high-temperature processes for the production or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals. These repairs or modifications to a manufacturing vessel typically require taking the vessel out of service, which in turn can cause thermal shock or thermal gradient damage to the refractory lining placed therein.

[0053] Furthermore, for the purposes of this description, "preheating" or "warming up" refers to exposing a metallurgical vessel or a manufacturing vessel to a gas-powered preheater before being exposed to molten metal or steel in the case of a metallurgical vessel, or before being exposed to an operating cycle in the case of a manufacturing vessel. Specifically, for a metallurgical vessel during operation, an empty metallurgical vessel should each be kept at a high temperature. Preheating or warming up in both metallurgical vessels and manufacturing vessels affects the performance of the refractory lining. An example of preheating used in a process for the production or refining of molten steel is the working refractory lining 34.

[0054] The preheating temperature can be measured by a thermocouple. Examples of this temperature measurement method used in the process for the production or refining of molten steel include the preheater thermocouple 2, or an optical pyrometer, which will be described in more detail below. The preheating temperature in the process for the production or refining of molten steel is typically in the range of 1500°F to 2200°F. However, since the working refractory lining used in the process for the production or refining of molten steel, such as the working refractory lining 34, usually contains graphite and carbon, any exposure to off-spec preheating directly affects carbon depletion and, as a result, affects the performance of the working refractory lining 34. Although not necessary, preheating of the working refractory lining used in the process for the production or refining of molten steel, such as the working refractory lining 34, is expected to shorten the refractory life of the working refractory lining and affect the future state of the working refractory lining.

[0055] Furthermore, the duration of preheating or temperature increase of the metallurgical vessel or production vessel is not predetermined. Instead, the duration depends on variables and circumstances defined in the area where the process is carried out, or the workplace. Such variables and circumstances include, but are not limited to, operational inconsistencies, process backlogs, availability of molten metal in the case of a metallurgical vessel, inclusions or availability of fuel in the charge mix or continuous feed mix in the case of a production vessel, unexpected repairs of process equipment, or shutdown due to emergency maintenance. Thus, the duration of preheating or temperature increase needs to be monitored by a recording mechanism such as the preheating or temperature increase recording device 24, which will be described in more detail below.

[0056] Furthermore, for the purposes of this description, the "residence time" for a process for the production or refining of molten steel is defined as the cumulative contact duration of the working refractory lining 34 with the molten steel and slag. The residence time is not predefined and depends greatly on the variables and circumstances defined in the area where the process takes place, i.e., the workplace. For example, the process flow in a steelworks can affect the cumulative contact duration of the working refractory lining 34 with the molten steel and slag, with values ranging from as low as 30 minutes to over 10 hours for each heating. Thus, the cumulative contact duration must be monitored by a recording mechanism such as the residence time recording device 23 described in more detail below.

[0057] Furthermore, for the purposes of this description, the "cycle time" for a high-temperature process for the production or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals is defined as the cumulative contact duration of the refractory lining with the high-temperature corrosion and erosion environment. This cycle time is not predefined and depends greatly on the variables and circumstances defined in the area or workplace where the process takes place. For example, the process flow in a non-metal factory can affect the cumulative contact duration of the refractory lining, so the cumulative contact duration needs to be monitored by a recording mechanism such as the cycle time recording device 423 described in more detail below.

[0058] Furthermore, particularly with respect to processes for the production or refining of molten steel, metallurgical vessels typically include agitation elements located at their bottoms. These purge an inert gas, such as argon or nitrogen, through the molten steel. The main purpose of this is to improve and facilitate the desulfurization of the molten steel, but it is also to improve alloying efficiency and the temperature uniformity of the molten steel. The agitation pressure is typically in the range of 120 psi to 180 psi, and the gas volume is typically between 5 and 50 scfm. The normal flow rate is generally 5 to 10 scfm for gentle agitation and rinsing, 15 to 25 scfm for moderate agitation during arc discharge, alloy addition, and homogenization, and 25 to 45 scfm for heavy desulfurization. The flow rate varies depending on the size of the vessel, the position of the plug, and the condition of the plug. The purge duration during heating can range from several minutes to over 30 minutes. The typical life of a purge plug is 500 minutes to 2000 minutes. The agitation pressure, flow rate, and time affect not only the life of the plug but also the local erosion of the working refractory lining 34. Therefore, as in the case of preheating and residence time, the parameters regarding the agitation of molten steel are not predetermined and depend on the efficiency of steel desulfurization. For example, the sulfur level is measured before tapping the molten steel. If the target value for desulfurization is not reached, additional agitation time, increased agitation pressure, increased flow rate, etc. are applied. Increases and rises in these parameters are known to result in a decrease in the life of the working refractory lining 34. These parameters can be monitored and recorded in the gas agitation control device 26, which will be further described below.

[0059] Furthermore, for the purposes of this description, with respect to processes for the production or refining of molten steel, the physical orientation of the metallurgical vehicle corresponds to the position of the metallurgical vehicle in relation to the overall space of the area in which the metallurgical vehicle is being used, such as a steelworks or any other facility dedicated to steel production.

[0060] Referring now to the drawings, which are for purposes of illustrating the preferred embodiments of the invention and not for purposes of limiting the same, the invention relating to processes for the production or refining of molten steel will be described with reference to FIGS. 1 - 3.

[0061] FIG. 1 is a schematic diagram showing an example of a predicted refractory performance measurement system 4. The system 4 is used to predict the future state, i.e., the performance, of a refractory lining that lines the inner surface of the outer wall of a metallurgical vessel for handling molten metal or molten steel. The predicted refractory performance measurement system 4 can be implemented in a steelworks, foundry, or other environments known to those skilled in the art as being suitable for melting, forming, and refining steel and metals. However, it is envisioned that substantial portions of the system 4 can be implemented in any environment where surface analysis, temperature analysis, process data analysis, and average life calculation of the refractory are desired.

[0062] The exemplary devices, units, modules, devices, and other components shown in FIG. 1 are hardware components that make up the system 4 and perform the methods and operations described herein with respect to FIGS. 2 and 3. Examples of hardware components are not limited to the devices, units, modules, and devices exemplified above, and can include controllers, sensors, generators, drivers, and any other electronic components known to those skilled in the art. Such components may be variably arranged according to design requirements and may communicate with each other through wired or wireless means.

[0063] In the non-limiting example described herein, the system 4 includes a computing complex 10. The computing complex 10 can include, but is not limited to, one or more processors 12 and one or more storage means 14. The processors 12 and storage 14 of the computing complex 10 can be oriented, positioned, or connected in any way to facilitate the proper operation of the computing complex 10. This includes, but is not limited to, wired configurations, wireless configurations, local configurations, wide area configurations, and any combination through which communication can be established between them through compatible network protocols.

[0064] Processor 12 is implemented by one or more processing elements. Such processing elements may be an array of logic gates, a controller and an arithmetic logic unit, a digital signal processor, a microcomputer, a programmable logic controller, a field programmable gate array, a programmable logic array, a microprocessor, or any other device or combination of devices known to those skilled in the art that can respond to instructions and execute in a defined manner to obtain the desired result.

[0065] For simplicity, the singular form "processor" may be used in the description of the exemplary processor 12 described herein, but in other examples, multiple processors 12 are used, or processor 12 includes multiple processing elements, or multiple types of processing elements, or both. In one example, the system 4 of hardware components includes multiple processors 12 of the computing complex 10, and in another example, the hardware components of the system 4 include an independent processor or another controller with a processor, and then perform data communication to receive data from the processor 12 of the computing complex 10. The processor 12 of the computing complex 10, together with the other components of the system 4 described below, may be defined as a hardware component. Similar to the processor 12, other hardware components including processing functions may be defined according to any one or more of different processing configurations, examples of which include a single processor, an independent processor, a parallel processor, single instruction single data (SISD) multiprocessing, single instruction multiple data (SIMD) multiprocessing, multiple instruction single data (MISD) multiprocessing, and multiple instruction multiple data (MIMD) multiprocessing. The processor 12 may be connected to the hardware components via a cable or a wireless network to provide instructions thereto, or connected to other processors to enable the multiprocessing function.

[0066] To implement the hardware components and execute the methods as described below, the instructions or software for controlling the hardware including the processor 12 or a processor within the system 4 are written, individually or collectively, to instruct or configure the hardware including the processor 12 or a processor within the system 4 to operate as a machine or special-purpose computer and perform the operations performed by the hardware components and the methods as described below, as a computer program, code segment, instruction, or any combination thereof. In one example, the instructions or software include machine code that is directly executable by the hardware including the processor 12 or a processor within the system 4, such as machine code generated by a compiler. In another example, the instructions or software include high-level code that is executable by the hardware including the processor 12 or a processor within the system 4 using an interpreter.

[0067] Based on the flowchart shown in FIG. 3 and the corresponding description herein, which disclose an algorithm for performing the operations performed by the hardware components and the methods as described above, a programmer skilled in the art can easily write the instructions or software.

[0068] The hardware components implemented in the system 4, such as the processor 12 or components linked to the processor 12, execute instructions or software, such as an operating system (OS) and one or more software applications operating on the OS, to perform the operations described below with respect to FIGS. 2 and 3.

[0069] Instructions or software, along with any associated data, data files, and data structures, for controlling hardware including the processor 12 or a processor within a system 4 implementing hardware components to execute a method as described below, are recorded, stored, or fixed in storage 14. Storage 14 of computing complex 10 generally refers to one or more memories that store instructions or software executed by processor 12. However, hardware components implemented in system 4 such as processor 12 or components linked to processor 12 may include local storage or may access, manipulate, process, create, and store data in storage 14 in response to the execution of instructions or software.

[0070] Storage 14 may represent that on one or more non-transitory computer-readable storage media. Storage 14 may represent a plurality of non-transitory computer-readable storage media linked together via a network of computing complex 10. For example, the non-transitory computer-readable storage media may be located in one or more storage facilities or one or more data centers remotely located from system 4 within computing complex 10. Such media may be connected to system 4 through the network of computing complex 10. The network of computing complex 10 enables data to be transferred from a non-transitory computer-readable storage media remotely located in a data center or storage facility to a non-transitory computer-readable storage media within storage 14 of computing complex 10 via the network. Further, storage 14 may represent both non-transitory computer-readable storage media located remotely and non-transitory computer-readable storage media located locally.

[0071] Examples of non-transitory computer-readable storage media include read-only memory (ROM), random access memory (RAM), flash memory, solid state memory, CD-ROM, CD-R, CD+R, CD-RW, CD+RW, DVD-ROM, DVD-R, DVD+R, DVD-RW, DVD+RW, DVD-RAM, BD-ROM, BD-R, BD-R LTH, BD-RE, magnetic tape, floppy disk, magneto-optical data storage device, optical data storage device, hard disk, solid state disk, and any device known to those skilled in the art, which store instructions or software and any associated data, data files, and data structures in a non-transitory manner and provide the instructions or software and any associated data, data files, and data structures to the processor 12 of the computing complex 10 or a processor within the system 4 including a processor so that the instructions can be executed by the processor. In one example, the instructions or software and any associated data, data files, and data structures are distributed and arranged on a network-connected computer system such that the instructions and software and any associated data, data files, and data structures are stored, accessed, and executed in a distributed manner by the processor 12.

[0072] Examples of hardware components within the system 4 other than the processor 12 and storage 14 of the computing complex 10 may include the terminal 6. The terminal 6 can include, for example, but is not limited to, user input, a display, or a combination thereof. In FIG. 1, the terminal 6 is illustrated as being connected to the computing complex 10. However, the embodiments disclosed herein are not limited thereto. For example, the terminal 6 may be connected directly to the processor 12, directly to the storage 14, to both the storage 14 and the processor 12, or to any other hardware component of the system 4.

[0073] The terminal 6 may be configured to display information contained in the storage 14 that has been processed by the processor 12 or input by the user. The processor 12 is responsible for determining what is to be displayed on the terminal 6. The storage 14 may be configured to store data generated by the processor 12 and input via the terminal 6. Applications, user inputs, and processor calculations may be stored in the storage 14 for access by the processor 12 in order to predict refractory performance.

[0074] Further examples of the hardware within the system 4 connected to the storage 14 may include a slag chemical composition measuring device 3, a laser scanner 20, a preheater thermocouple 2, an infrared camera 22, a residence time recording device 23, a preheat recording device 24, a gas stirring control device 26, a ladle thermocouple 25, and an azimuth laser 19. The storage 14 can receive data from these hardware components by any wired or wireless method known to those skilled in the art and transmit the received and stored data to the processor 12 by any wired or wireless method known to those skilled in the art for further processing. The operation of these components will be described in more detail in the following description.

[0075] FIG. 2 is a schematic diagram showing an example in which a refractory lining is lined on the inner surface of the outer walls of the ladle containers 16, 18, where the future state of the refractory lining will be predicted by the predictive refractory performance measurement system 4. The ladle container 16 does not contain molten metal or molten steel and is thus referred to as the "empty ladle container 16". The ladle container 18 contains molten metal or molten steel and is thus referred to as the "filled ladle container 18". The ladle containers 16 and 18 in FIG. 2 represent secondary refining and transportation containers such as steel ladles.

[0076] Each of the ladle vessels 16, 18 is lined with the same refractory. In the example shown in FIG. 2, a preliminary refractory lining 32 is lined on the inner surface of the outer walls of the ladle vessels 16, 18. The working refractory lining 34 is lined on top of the preliminary refractory lining 32.

[0077] Since the working refractory lining 34 is lined on top of the preliminary refractory lining 32, the preliminary refractory lining 32 typically has a relatively long lifespan. For example, the preliminary refractory lining 32 might be able to have a lifespan of one year. On the other hand, during steelmaking heating, the working refractory lining 34 is directly exposed to the molten metal or molten steel placed inside the ladle vessels 16, 18. Therefore, the lifespan of the working refractory lining 34 is typically quite short. Depending on the severity of the steelmaking process carried out during heating, the working refractory lining 34 might only last for two weeks. Thus, the working refractory lining 34 of the empty ladle vessel 16 is the same as that of the filled ladle vessel 18, but during heating, the working refractory lining 34 of the filled ladle vessel 18 is assumed to be affected by the molten metal or molten steel contained therein. Therefore, there is a high possibility that the structural conditions of the working refractory lining 34 of the empty ladle vessel 16 before heating and the structural conditions of the working refractory lining 34 of the empty ladle vessel 16 after each heating are significantly different.

[0078] As described above, the system 4 includes at least one laser scanner 20. The laser scanner 20 can be either stationary or mobile. The laser scanner 20 is configured to scan the working refractory lining 34 of the empty ladle vessel 16 before and after heating that involves handling molten metal or molten steel. The laser scanner 20 may have a Class 1 eye-safe laser with the ability to scan at a frequency of 1,000,000 points per second. The laser scanner 20 may also have a scan speed of 20 seconds and an accuracy of 1 - 2 mm.

[0079] The laser scanner 20 is supported by a laser support device 21. The laser support device 21 may be a stationary support when the laser scanner 20 is stationary, or a moving support when the laser scanner 20 is moving. When the laser scanner 20 is mobile, the laser support device 21 may be any support means known to those skilled in the art that is suitable for moving the mobile laser scanner 20. When the laser scanner 20 is stationary, the laser support device 21 may be any means of fixedly supporting that is known to those skilled in the art to be suitable for fixing the stationary laser scanner 20.

[0080] The scan function performed by the laser scanner 20 includes, but is not limited to, collecting structural data that observes the respective structural conditions before and after heating of the working refractory lining 34 in the empty ladle container 16 before and after the empty ladle container 16 is filled with molten metal or molten steel and thereby becomes the filled ladle container 18. This data is provided to the computing complex 10 for storage in the storage device 14 and / or reference by the processor 12 regarding the structural state of the working refractory lining 34.

[0081] The system 4 may also include one or more infrared cameras 22 capable of performing one or more infrared scans of the outer surface of the outer wall of the filled ladle container 18 during heating to collect data related to the temperature of the outer surface of the outer wall of the filled ladle container 18 during heating.

[0082] In one example, infrared cameras 22 may be placed at multiple locations within the processing plant to strategically measure the temperature of the outer surface of the outer wall of the filled ladle container 18 as it moves from the location where the filled ladle container 18 is filled with molten steel to the secondary steelmaking locations throughout the processing plant, including the location where refining is performed. In another example, an infrared camera 22 may be placed at a location within the processing plant to strategically measure the temperature of the outer surface of the outer wall of the empty ladle container 16 before and after heating that involves handling molten metal or molten steel. The thermal inconsistencies of the empty ladle container 16 can be identified even when the empty ladle container 16 is preheated. The temperature data collected from the infrared camera 22 may be mapped by the processor 12 to identify deteriorated portions of the working refractory lining 34.

[0083] The infrared camera 22 may be any infrared camera, provided that those skilled in the art know that it is suitable for imaging the outer surface of the outer wall of the metallurgical container when filled with molten steel. The temperature data may be provided to the computing complex 10 for storage in the storage device 14 and / or consideration by the processor 12 regarding the structural conditions of the working refractory lining 34.

[0084] The temperature data of the empty ladle container 16 or the filled ladle container 18 obtained by the infrared camera 22 can be calculated from the perspective of thermal resistivity and heat flux using analysis utilizing ASTM680 - 14 or heat conduction calculation software developed for refractory design, but the disclosed embodiments are not limited thereto. For example, any software or analysis method known to those skilled in the art that can calculate such temperature data can be utilized.

[0085] Furthermore, the laser scan data, temperature data, or a combination thereof communicated to the computing complex 10 for reference by the processor 12 can additionally be referenced together with other measured predetermined operating parameters stored in the storage 14 that are waiting for communication to the processor 12 and reference by the processor 12. The measured operating parameters may be supplied to the computer complex 10 for reference by the processor 12 through the aforementioned hardware means including, but not limited to, the slag chemical composition measuring device 3, the preheater thermocouple 2, the residence time recording device 23, the preheat recording device 24, the gas stirring control device 26, and the ladle thermocouple 25. The predetermined operating parameters may be stored in the storage 14 for future reference related to future state prediction for the working refractory lining 34 and may be supplied to the computer complex 10 via the terminal 6 by user input or historical data previously processed by the processor 12.

[0086] The specified operating parameters may include, but are not limited to, historical data related to one or more refractories applied to one or more past refractory linings lining the inner surface of the outer wall of a past metallurgical vessel that handled molten metal or molten steel, the initial chemical composition and origin of the working refractory lining 34, the initial physical design of the working refractory lining 34, the steel grade required to be produced from the molten steel during heating, the physical and chemical properties and amounts of the charge mix components added to the metallurgical vessel during heating to produce the desired steel grade from the molten steel, the physical and chemical properties and amounts of the alloys added to the metallurgical vessel during heating for secondary steelmaking and refining, the physical and chemical properties and amounts of the slag forming agents added to the molten steel in the metallurgical vessel during heating to form a slag that absorbs non-metallic components from the molten steel to produce the desired steel grade from the molten steel, the physical and chemical properties and amounts of the flux additives added to the molten steel in the metallurgical vessel during heating to optimize the fluidity of the formed slag to produce the desired steel grade from the molten steel, and the history of the metallurgical vessel during the period when the working refractory lining 34 is lining the liner surface of the outer wall of the metallurgical vessel, or any other relevant specified operating parameters identified in a particular metal manufacturing operation.

[0087] For the purposes of the present application, the physical design of the working refractory lining 34 may include, but is not limited to, the structural details of the working refractory lining 34, the shape of the refractory components in the working refractory lining 34, the size of the refractory components in the working refractory lining 34, and the combination of the refractory components in the working refractory lining 34.

[0088] The measured operating parameters may include, but are not limited to, the preheating duration while an empty metallurgical vessel is preheated before heating, the residence time defined by the cumulative contact duration while molten steel, slag, or a combination thereof is in contact with the working refractory lining 34 during the process of manufacturing molten steel, the magnitude of the stirring pressure applied by stirring the molten steel in the metallurgical vessel, the flow rate of the inert gas applied to the molten steel in the metallurgical vessel during stirring of the molten steel in the metallurgical vessel, the stirring duration during which the molten metal is stirred, or other relevant measured operating parameters specified in a particular metal manufacturing operation.

[0089] Using the above data, the processor 12 can calculate the exposure effect of heating on the working refractory lining 34 of the metallurgical vessel and predict the future state of the working refractory lining 34 after one or more subsequent heatings. The exposure effect of heating on the working refractory lining 34 may be calculated by comparing the structural conditions of the working refractory lining 34 before heating and the structural conditions of the working refractory lining 34 after heating. Based on the calculated exposure effect, the future state of the working refractory lining 34 after one or more subsequent heatings is predicted. In other words, the exposure effect of the first heating can be used to predict the future state of the working refractory lining 34 after the second heating, the third heating, etc. The processor 12 may refer to the data from all the data sources mentioned above, but is not limited thereto, and it is also conceivable to include other data sources not mentioned in this specification.

[0090] As an example, to supplement the prediction of the future state of the working refractory lining 34, the temperature data collected from the infrared camera 22 may be correlated with the structural conditions of the working refractory lining 34 before handling the molten steel and the structural conditions of the working refractory lining 34 after handling the molten steel, thereby supplementing the calculation of the exposure effect of the working refractory lining 34. This enables a more accurate prediction of the future state.

[0091] In another example, to supplement the prediction of the future state of the working refractory lining 34, the calculation of the exposure impact of the working refractory lining 34 may be supplemented by considering, in correlation with the collected structural condition data, the operational impact that one or more of the aforementioned predetermined or measured operating parameters have on the exposure impact of heating on the working refractory lining 34.

[0092] As an example, historical data regarding one or more refractories applied to one or more past refractory linings lined on the inner surface of the outer wall of a past metallurgical vessel that handled molten metal or molten steel can be used to establish a historical pattern of exposure impact. Such a historical pattern can complement the comparison between the structural condition of the working refractory lining 34 before handling molten metal or molten steel and the structural condition of the working refractory lining 34 after handling molten metal or molten steel, and its correlation with the temperature data collected from the infrared camera 22. Such historical data may be accumulated in the storage 14 of the computing complex 10 after the calculation of the exposure impact so that the processor 12 can predict the future state of subsequent working refractory linings with higher accuracy for each successive heating.

[0093] Regarding the use of operating parameters measured to assist in the calculation of the exposure impact, a ladle thermocouple 25 may be provided to measure the temperature of the molten metal or molten steel in the filled ladle vessel 18. As an example, the ladle thermocouple 25 may be inserted into the molten steel through the opening 40 of the filled ladle vessel 18 to measure the temperature of the molten steel during or at the end of the secondary steelmaking process (e.g., at the end of the refining process). The ladle thermocouple 25 can provide the measured temperature data to the computing complex 10 for consideration by the processor 12 during the calculation of the exposure impact in accordance with the prediction of the future state of the working refractory lining 34.

[0094] Furthermore, a slag chemical composition measuring device 3 may be provided to measure the chemical composition of slag generated in the metallurgical vessel during the secondary steelmaking process. As described above, in order to measure the chemical composition, it is necessary to cool the sample of the slag. The slag chemical composition measuring device 3 may be, for example, a fluorescent X-ray device, and thereby, a fluorescent X-ray analysis technique for calculating the chemical composition is adopted. The slag chemical composition measuring device 3 can provide the measured chemical composition of the slag to the computing complex 10 so as to be referred to by the processor 12 during the calculation of the exposure effect according to the prediction of the future state of the working refractory lining 34.

[0095] Furthermore, a preheater thermocouple 2 may be provided to measure the temperature of the metallurgical vessel when the metallurgical vessel is empty and preheated before being filled with molten metal or molten steel. The preheater thermocouple 2 can provide the measured preheater temperature to the computing complex 10 for consideration by the processor 12 during the calculation of the exposure effect according to the prediction of the future state of the working refractory lining 34.

[0096] To monitor the duration of the residence time, a recording mechanism such as the residence time recording device 23 mentioned in this specification may be used to measure the cumulative contact duration while the molten metal, slag, or a combination thereof is in contact with the refractory lining during heating.

[0097] Furthermore, to monitor the duration of the preheating, a recording mechanism such as the preheating recording device 24 mentioned in this specification may be used to record the duration of the preheating performed on the empty metallurgical vessel before heating. Specifically, the duration of the preheating can be measured by the preheating recording device 24 from a few minutes to several days. The preheating recording device 24 can be incorporated into a gas-type preheating device together with an automatic gas shut-off device.

[0098] Furthermore, various stirring parameters including, but not limited to, the magnitude of the stirring pressure applied by stirring the molten steel in the filled metallurgical vessel using a control mechanism such as the gas stirring control device 26, the flow rate of the inert gas applied to the molten steel during stirring of the molten steel in the filled metallurgical vessel, and the stirring duration while the molten steel is being stirred may be measured.

[0099] Before the laser scan of the working refractory lining 34 by the laser scanner 20, an orientation laser 19 may be provided to scan the empty ladle container 16 to identify the physical orientation of the empty ladle container 16. The scan performed by the orientation laser 19 assists the laser scan of the working refractory lining 34 by the laser scanner 20 and helps to increase its accuracy. The physical orientation of the empty ladle container 16 is related to the position of the empty ladle container 16 relative to the process or facility in which the empty ladle container 16 is being used. The orientation laser 19 provides the identified physical orientation of the metallurgical vessel to the computing complex 10 for consideration by the processor 12 to determine the correct positioning of the empty ladle container 16 and to be used for the accurate calculation of the exposure effect in accordance with the prediction of the future state of the working refractory lining 34.

[0100] More specifically, the data from the orientation laser 19 may enable the processor 12 to calculate thickness measurements from the spatial measurements of the surface of the working refractory lining 34. Such measurements cannot be derived unless the physical position and orientation of the empty ladle container 16 are estimated or accurately known. The data from the orientation laser 19 may enable the processor 12 to accurately know the physical position and orientation of the empty ladle container 16.

[0101] The azimuth laser 19 is shown in FIG. 2 as being disposed directly below the empty ladle container 16, but the embodiments disclosed herein are not limited thereto. For example, the azimuth laser 19 can be disposed at any safe and unobstructed location where the outer wall of the empty ladle container 16 can be directly viewed, so the azimuth laser 19 will be disposed to scan the bottom and lower part of the empty ladle container 16. It should be noted that the physical azimuth determination by the azimuth laser 19 can be supplemented through the data provided by the laser scanner 20 regarding the empty ladle container 16.

[0102] Next, referring to FIGS. 2 and 3, a method 100 for predicting the future state of a working refractory lining 34 that is lined on the inner surface of the outer wall of a metallurgical container and is exposed to heating while the refractory lining is exposed to molten metal or molten steel is described.

[0103] For the purposes of the description of method 100, "metallurgical container" may refer to a ladle container that is exposed to molten metal or molten steel. The ladle containers in method 100 generally refer to the empty ladle container 16 and the filled ladle container 18 in situations where it does not matter whether the ladle container is empty or full. Further, in one example, the empty ladle container 16 receives molten steel from a furnace when the molten steel is tapped therefrom. Thus, the empty ladle container 16 transitions to the filled ladle container 18 when the molten steel is tapped from the furnace into the empty ladle container 16.

[0104] Furthermore, method 100 is not limited to the process in which the metallurgical container is transported, but during the heating in method 100, it is assumed that the ladle containers 16 and 18 are transported to a processing location or the entire factory through transportation means known to those skilled in the art, such as cranes, conveyors, rails, and bearings, but is not limited thereto. Further, the computing complex 10 including the processor 12 and any other control units enables the control of all processes including, but not limited to, scanning, measuring, transporting, transferring metal, observing, collecting, determining, predicting, and considering.

[0105] A schematic diagram of the transportation of the ladle container 16 and the ladle container 18 is shown in FIG. 2. The empty ladle container 16 and the filled ladle container 18 are shown separately. In the embodiment, the empty ladle container 16 may be initially scanned to identify the physical orientation of the empty ladle container 16 before any scan of the working refractory lining 34. Such an initial scan may be performed by the azimuth laser 19 described above. The physical orientation of the empty ladle container 16 may be referenced by the processor 12 during any further consideration, calculation, and prediction by the processor 12 regarding the ladle container 16 or the ladle container 18.

[0106] Furthermore, after the scan of the physical orientation and before any scan of the working refractory lining 34, while the empty ladle container 16 is being preheated in preparation for heating, the preheating temperature and the preheating duration while the empty ladle container 16 is receiving preheating before heating may be recorded. The preheating temperature may be measured by the preheater thermocouple 2, and the preheating duration may be recorded by the preheating recording device 24. The preheating temperature and the preheating duration may be used by the processor 12 as measurement parameters when considering the operational influence of the steelmaking-related operating parameters on the structural conditions of the working refractory lining 34 after handling molten metal or molten steel.

[0107] Further measurements of operating parameters may be performed during heating, for example, but not limited to, measurement of the temperature of molten metal or molten steel in the filled ladle vessel 18 by the ladle thermocouple 25, measurement of the chemical composition of the slag in the filled ladle vessel 18 by the slag chemical composition measuring device 3, measurement of the cumulative contact duration while the molten steel, slag, or a combination thereof is in contact with the working refractory lining 34 during heating by the residence time recording device 23, and measurement of various stirring parameters by the gas stirring control device 26, which will be described in detail below. The predetermined operating parameters as described above can be provided to the computing complex 10 when convenient. However, as described above and further described below, any predetermined operating parameter provided to the computing complex 10 will be referred to by the processor 12 in calculating the exposure effect on the working refractory lining 34.

[0108] After any additional preparation steps are completed and before heating, a laser scan of the working refractory lining 34 of the empty ladle vessel 16 is performed (S101). The laser scan before heating can be executed by the laser scanner 20. Also, the implementation of the laser scan before heating may include the collection of data regarding the structural conditions of the working refractory lining 34 before heating.

[0109] Next, heating is performed, during which the empty ladle vessel 16 is filled with molten metal or molten steel, thereby becoming the filled ladle vessel 18. This is shown in the flow of FIG. 2, where the empty ladle vessel 16 is illustrated as being at a certain part of the process and the filled ladle vessel 18 is illustrated as being at a later point in the process. During heating, the filled ladle vessel 18 is emptied as shown in the flow of FIG. 2, becoming the empty ladle vessel 16.

[0110] After the heating is completed, the laser scan of the working refractory lining 34 of the empty ladle container 16 is performed again (S102). Similar to the implementation of the laser scan before heating, the laser scan after heating can also be executed by the laser scanner 20. Furthermore, the implementation of the laser scan after heating can also include the collection of data related to the structural state of the working refractory lining 34 after heating.

[0111] After the laser scan before heating and the laser scan after heating, the processor 12 calculates the exposure effect of heating on the working refractory lining 34 (S103). The processor 12 can determine the exposure effect by comparing the collected pre-heating structural condition data with the collected post-heating structural condition data. After calculating the exposure effect of heating, the processor 12 predicts the future state of the working refractory lining 34 after one or more subsequent heatings based on the calculated exposure effect of heating (S104).

[0112] This prediction provides extremely important information for determining whether the ladle container can be reused using the working refractory lining 34 or whether the working refractory lining 34 needs to be replaced. As a result, accidents that cause excessive structural damage to the ladle container can be avoided, leading to a reduction in downtime, an improvement in efficiency, and cost savings.

[0113] As an example, during heating, one or more infrared scans may be performed on the outer surface of the outer wall of the filled ladle container 18 by the infrared camera 22. With this scan, the infrared camera 22 can collect data regarding the temperature of the outer surface detected during heating. This temperature data can be correlated with the collected structural condition data to more accurately determine the effect of exposure and predict the future state.

[0114] In another embodiment, the calculation of the exposure effect correlates with the collected structural condition data and, optionally, in this particular embodiment, with the collected temperature data from the infrared scan, and takes into account the operating impact on the working refractory lining 34 during heating, where one or more of the measured or predetermined operating parameters are considered.

[0115] The predetermined operating parameters include, but are not limited to, the following, which include the predetermined operating parameters described previously herein: historical data regarding one or more refractories applied to one or more past refractory linings that handled molten metal, the initial chemical composition and origin of the working refractory lining 34, the initial design of the working refractory lining 34, the steel type required to be produced during heating, the physical and chemical properties and amounts of the filler mix components added to the ladle vessel 18 filled during heating, the physical and chemical properties and amounts of the alloy added to the ladle vessel 18 filled during heating, the physical and chemical properties and amounts of the slag former added to the ladle vessel 18 filled during heating, the physical and chemical properties and amounts of the flux additive added to the ladle vessel 18 filled during heating, and the history of the ladle vessel 16 and the ladle vessel 18 during the period in which the working refractory lining 34 is lined inside.

[0116] The measured operating parameters include, but are not limited to, the following, which are the measured operating parameters described above in this specification: the preheating temperature measured by the preheater thermocouple 2 while the empty ladle container 16 is being preheated before heating, the preheating duration measured by the preheating recording device 24 while the empty ladle container 16 is being preheated before heating, the temperature measurement value of the molten metal or molten steel in the filled ladle container 18 by the ladle thermocouple 25, the measurement of the cumulative contact duration by the residence time recording device 23 while the molten steel, slag, or a combination thereof is in contact with the working refractory lining 34 during heating, and the magnitude of the stirring pressure applied by stirring the molten metal in the filled ladle container 18 during heating, the flow rate of the inert gas applied to the molten metal in the filled ladle container 18 during stirring, the stirring duration for stirring the molten metal, etc., including, but not limited to, the measured values of various stirring parameters by the gas stirring control device 26.

[0117] Next, referring to the drawings, where the illustrations are for explaining the preferred embodiments of the present invention and are not for limiting it, an invention related to high-temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically called non-metals will be described with reference to FIGS. 4 to 6.

[0118] FIG. 4 is a schematic diagram showing another example of a predicted refractory performance measurement system. The predicted refractory performance measurement system 404 is used to predict the future state, i.e., the performance, of the refractory lining lined on the inner surface of the outer wall of a manufacturing container for handling glass, cement, lime, chemicals, oil and gas, or other materials typically called non-metals. The predicted refractory performance measurement system 404 can be implemented in factories, workplaces, production areas, or other environments known to those skilled in the art to be suitable for the melting, shaping, sintering, densification, conversion, and purification of non-metals. However, it is assumed that a substantial part of the system 404 can be implemented in any environment where surface analysis, temperature analysis, process data analysis, and life calculation of the refractory are desired.

[0119] Both systems 4 and 404 are similar in that they are designed to calculate the state of the refractory layer used in an industrial process after exposure to corrosive substances that can cause deterioration of the refractory layer in the industrial process. Much of the hardware of systems 4 and 404 is interchangeable with each other, but some hardware is unique to system 404. Further, some of the hardware used in system 4 is not necessary for the operation of system 404. Further, some of the corresponding hardware of systems 4 and 404 may perform their functions independently because many of the processes and measurement components used by system 4 are different from the processes used by system 404.

[0120] Similar to system 4 and the cases of FIGS. 1 - 3, the exemplary devices, units, modules, devices, and other components shown in the figures are hardware components that make up system 404 and perform the methods and operations described herein with respect to FIGS. 5 and 6. Examples of hardware components are not limited to the above - mentioned exemplary devices, units, modules, and devices, and can include controllers, sensors, generators, drivers, and any other electronic components known to those skilled in the art. Such components may be variably arranged according to design requirements and may communicate with each other through wired or wireless means.

[0121] In the non-limiting examples described herein, system 404 includes computing complex 410. Computing complex 410 can include, but is not limited to, one or more processors 412 and one or more storage means 414. The processors 412 and storage 414 of computing complex 410 can be oriented, positioned, or connected in any way to facilitate the proper operation of computing complex 410. This includes, but is not limited to, wired configurations, wireless configurations, local configurations, wide area configurations, and any combination through which communication can be established between them through compatible network protocols.

[0122] Processor 412 is implemented by one or more processing elements. Such processing elements can be an array of logic gates, a controller and an arithmetic logic unit, a digital signal processor, a microcomputer, a programmable logic controller, a field programmable gate array, a programmable logic array, a microprocessor, or any other device or combination of devices known to those skilled in the art that can respond to instructions and execute in a defined manner to obtain the desired result.

[0123] For simplicity, the description of the exemplary processor 412 described herein may use the singular form "processor", but in other examples, multiple processors 412 are used, or the processor 412 includes multiple processing elements, or multiple types of processing elements, or both. In one example, the system 404 of hardware components includes multiple processors 412 of the computing complex 410, and in another example, the hardware components of the system 404 include an independent processor or another controller that includes a processor, which then communicates data to receive data from the processor 412 of the computing complex 410. The processor 412 of the computing complex 410 can be defined as a hardware component, along with other components of the system 404 described below. Similar to the processor 412, hardware components that include processing capabilities may be defined according to any one or more of different processing configurations, examples of which include a single processor, an independent processor, a parallel processor, single instruction single data (SISD) multiprocessing, single instruction multiple data (SIMD) multiprocessing, multiple instruction single data (MISD) multiprocessing, and multiple instruction multiple data (MIMD) multiprocessing. The processor 412 may be connected to the hardware components via a cable or wireless network to provide instructions thereto, or connected to other processors to enable multiprocessing capabilities.

[0124] Instructions or software for controlling hardware to implement hardware components and execute a method as described below, individually or collectively, direct or configure the hardware including processor 412 or a processor within system 404 to operate as a machine or special-purpose computer and perform the operations performed by the hardware components and the method as described below, and are written as a computer program, code segment, instruction, or any combination thereof. In one example, the instructions or software include machine code directly executable by the hardware including processor 412 or a processor within system 404, such as machine code generated by a compiler. In another example, the instructions or software include high-level code executable by the hardware including processor 412 or a processor within system 404 using an interpreter.

[0125] A programmer, being a person skilled in the art, can easily write the instructions or software based on the flowchart shown in FIG. 6, which discloses an algorithm for performing the operations performed by the hardware components and the method as described above, and the corresponding description herein regarding high-temperature processes for the manufacture or purification of glass, cement, lime, chemicals, oil and gas, or other materials typically referred to as non-metals.

[0126] Hardware components implemented in system 404, such as processor 412 or components linked to processor 412, execute instructions or software, such as an operating system (OS) and one or more software applications operating on the OS, to perform the operations described below with respect to FIGS. 5 and 6.

[0127] Hardware including the processor 412 or a processor within the system 404 implementing hardware components is controlled to execute a method as described below by instructions or software, and any associated data, data files, and data structures are recorded, stored, or fixed in the storage 414. The storage 414 of the computing complex 410 generally refers to one or more memories storing instructions or software executed by the processor 412. However, hardware components implemented in the system 404 such as the processor 412 or components linked to the processor 412 may include local storage or access, operate on, process, create, and store data in the storage 414 in response to the execution of instructions or software.

[0128] The storage 414 may represent that on one or more non-transitory computer-readable storage media. The storage 414 may represent a plurality of non-transitory computer-readable storage media linked together via the network of the computing complex 410. For example, the non-transitory computer-readable storage media may be disposed in one or more storage facilities or one or more data centers remotely located from the system 404 within the computing complex 410. Such media may be connected to the system 404 through the network of the computing complex 410. The network of the computing complex 410 enables non-transitory computer-readable storage media remotely located in a data center or storage facility to transfer data to non-transitory computer-readable storage media within the storage 414 of the computing complex 410 via the network. Further, the storage 414 may represent both non-transitory computer-readable storage media remotely located and non-transitory computer-readable storage media locally located.

[0129] Examples of non-transitory computer-readable storage media include read-only memory (ROM), random access memory (RAM), flash memory, solid state memory, CD-ROM, CD-R, CD+R, CD-RW, CD+RW, DVD-ROM, DVD-R, DVD+R, DVD-RW, DVD+RW, DVD-RAM, BD-ROM, BD-R, BD-R LTH, BD-RE, magnetic tape, floppy disk, magneto-optical data storage device, optical data storage device, hard disk, solid state disk, and any device known to those skilled in the art, which store instructions or software and any associated data, data files, and data structures in a non-transitory manner and provide the instructions or software and any associated data, data files, and data structures to a processor 412 in computing complex 410 or a processor within system 404 including a processor in hardware so that the processor can execute the instructions. In one example, the instructions or software and any associated data, data files, and data structures are distributed over a network-coupled computer system such that the instructions and software and any associated data, data files, and data structures are stored, accessed, and executed in a distributed manner by processor 412.

[0130] Examples of hardware components within system 404 other than processor 412 and storage 414 of computing complex 410 may include terminal 406. Terminal 406 can include, for example, but is not limited to, user input, display, or combinations thereof. In FIG. 4, terminal 406 is shown as being connected to computing complex 410. However, the embodiments disclosed herein are not limited thereto. For example, terminal 406 may be connected directly to processor 412, directly to storage 414, to both storage 414 and processor 412, or to any other hardware component of system 404.

[0131] The terminal 406 may be configured to display information contained in the storage 414 that has been processed by the processor 412 or input by the user. The processor 412 oversees determining what is to be displayed on the terminal 406. The storage 414 may be configured to store data generated by the processor 412 and input via the terminal 406. Applications, user inputs, and processor calculations may be stored in the storage 414 for access by the processor 412 to predict refractory performance.

[0132] Further examples of the hardware of the system 404 connected to the storage 414 are illustrated in at least one of FIGS. 4 or 5 and may include at least one laser scanner 420, auxiliary thermocouple 402, one or more outer view infrared cameras 422, one or more inner view infrared cameras 403, cycle time recorder 423, auxiliary recorder 424, ambient measurement thermocouple 425, non-metal measurement thermocouple 428, azimuth laser 419, one or more pressure sensors 407 for radar / tomography scans, one or more gas sensors 409, and one or more tomography sensors 411, etc.

[0133] Some of this hardware may only be utilized in specific applications. For example, the functional use of the tomography sensor 411 for radar / tomography scans may be limited to applications for radar wave differential measurements when the system 404 is used to measure the refractory layer in a glass melting furnace.

[0134] Furthermore, the functional use of the pressure sensor 407 and the gas sensor 409 may be limited to petrochemical applications where the manufacturing vessel 416 includes a burner system, uses variable fuel supply, or is under pressure and exposed to the presence of gas, and the system 404 is employed to measure the refractory lining 434. Specifically, the pressure measurements obtained by the pressure sensor 407 and the gas type measurements obtained by the gas sensor 409 may be communicated to the processor 412 to consider how exposure to the pressure and gas composition within the manufacturing vessel 416 affects the lifespan of the refractory lining 434.

[0135] Furthermore, the functional use of the glass draw speed calculator via the processor 412 may be further configured to calculate the glass draw speed, which represents the rate at which glass is melted within the manufacturing vessel 416 and is typically expressed in tons of glass melted per day. In such calculations, consideration may be given to how the rate at which glass is processed within the manufacturing vessel 416, i.e., the amount of material passing through the manufacturing vessel 416 per day, affects the lifespan of the refractory lining 434.

[0136] The storage 414 can receive data from these hardware components by any wired or wireless method known to those skilled in the art, and communicate the received and stored data to the processor 412 by any wired or wireless method known to those skilled in the art for further processing. The operation of these components will be described in more detail in the following description.

[0137] FIG. 5 is a schematic diagram showing an example in which the inner surface of the outer wall of the manufacturing vessel 416 is lined with a refractory lining 434, and the future state of the refractory lining 434 will be predicted by the predictive refractory performance measurement system 404. In the example shown in FIG. 5, the refractory lining 434 is lined on the inner surface of the outer wall of the manufacturing vessel 416.

[0138] Depending on the severity of the manufacturing process carried out during the operating cycle, the refractory lining 434 may last only a few months. During the operating cycle, the refractory lining 434 of the manufacturing vessel 416 is assumed to be affected by molten liquids, or high-temperature, abrasive, and erosive solids, or high-temperature, corrosive gases. Therefore, the structural conditions of the refractory lining 434 of the manufacturing vessel 416 after each operating cycle may be significantly different from those of the refractory lining 434 of the manufacturing vessel 416 before each operating cycle carried out.

[0139] As described above, the system 404 includes at least one laser scanner 420. The laser scanner 420 may be stationary or mobile. The laser scanner 420 is configured to scan the refractory lining 434 before and after the operating cycle of handling non-metals. The laser scanner 420 may have a Class 1 eye-safe laser with the ability to scan at a frequency of 1,000,000 points per second. The laser scanner 420 may also have a scan speed of 20 seconds and an accuracy of 1 - 2 mm.

[0140] The laser scanner 420 is supported by a laser support device 421. The laser support device 421 may be a stationary support when the laser scanner 420 is stationary, or a moving support when the laser scanner 420 is moving. When the laser scanner 420 is mobile, the laser support device 421 may be any support means known to those skilled in the art suitable for moving the mobile laser scanner 420. When the laser scanner 420 is stationary, the laser support device 421 may be any means of fixedly supporting known to those skilled in the art suitable for fixing the stationary laser scanner 420.

[0141] The scanning function performed by the laser scanner 420 includes, but is not limited to, collecting structural data that observes the structural conditions of the refractory lining 434 before and after the operating cycle. This data is provided to the computing complex 410 for storage in the storage device 414 and / or examination by the processor 412 regarding the structural state of the refractory lining 434.

[0142] The system 404 may also include one or more outer view infrared cameras 422 capable of performing one or more infrared scans of the outer surface of the outer wall of the production vessel 416 during the operating cycle to collect data regarding the temperature of the outer surface of the outer wall of the production vessel 416 during the operating cycle. The system 404 may further include one or more inner view infrared cameras 403 capable of performing one or more infrared scans of the inner surface of the outer wall of the production vessel 416 during the operating cycle to collect data regarding the temperature of the inner surface of the outer wall of the production vessel 416 during the operating cycle.

[0143] In one example, the outer view infrared camera 422 may be placed at several locations around the outer wall of the production vessel 416 in order to strategically measure the temperature of the outer surface of the outer wall of the production vessel 416. Temperature measurements during and between operating cycles are recorded by the outer view infrared camera 422 and can be analyzed for thermal inconsistencies. The temperature data collected from the outer view infrared camera 422 may then be mapped by the processor 412 to identify degraded portions of the refractory lining 434.

[0144] In another example, the inner view infrared camera 403 may be placed at a location that allows for measurement of the temperature of the inner surface of the outer wall of the production vessel 416. Such locations may include the inlet opening 440 of the production vessel 416, the outlet opening 418 of the production vessel 416, or any other opening in the structure of the production vessel 416 known to those skilled in the art to allow the inner view infrared camera 403 to measure the temperature of the inner surface of the outer wall of the production vessel 416, but are not limited thereto.

[0145] The outer view infrared camera 422 may be any infrared camera known to those skilled in the art to be suitable for imaging the outer surface of the outer wall of the production vessel 416 when the temperature of the production vessel 416 rises during the operating cycle. The inner view infrared camera 403 may be any infrared camera known to those skilled in the art to be suitable for imaging the inner surface of the outer wall of the production vessel 416 when the temperature of the production vessel 416 rises during the operating cycle.

[0146] Temperature data from the outer view infrared camera 422 and the inner view infrared camera 403 may be provided to the computing complex 410 for storage in the storage 414 and / or consideration by the processor 412 with respect to the structural conditions of the refractory lining 434. Although the temperature data obtained by the outer view infrared camera 422 can be calculated from the perspective of thermal resistivity and heat flux using the analysis utilizing ASTM 680-14 or heat transfer calculation software developed for refractory design, the disclosed embodiments are not limited thereto. For example, any software or analysis method known to those skilled in the art capable of calculating such temperature data can be utilized.

[0147] The temperature measurements from the inner view infrared camera 403 during the operating cycle can serve to complement the temperature measurements from the environmental measurement thermocouple 425 or the non-metallic measurement thermocouple 428.

[0148] As described above, when the production vessel 416 is a glass melting furnace or a similar vessel used for glass processing, a radar / tomography scan via the tomography sensor 411 may be used for measuring the thickness of the refractory lining 434, detecting the occurrence rate of glass impregnation into the refractory lining 434 during the operating cycle, or a combination thereof. The radar / tomography measurement via the tomography sensor 411 is performed from the outer surface of the outer wall of the production vessel 416. The tomography sensor 411 uses radar wave technology to identify the density difference between the glass being processed and the refractory lining 434 during the operating cycle.

[0149] Furthermore, whether the above-mentioned or the below-mentioned, the laser scan data, temperature data, radar data, pressure data, gas data, glass drawing speed data, or a combination thereof, which is communicated to the computing complex 410 for reference by the processor 412, can be additionally considered together with other measured predetermined operating parameters stored in the storage 414 that are waiting for communication to the processor 412 and consideration by the processor. The measured operating parameters can be supplied to the computer complex 410 for reference by the processor 412 through the aforementioned hardware means including, but not limited to, the pressure sensor 407, gas sensor 409, auxiliary thermocouple 402, cycle time recorder 423, tomography sensor 411, laser scanner 420, inner view infrared camera 403, outer view infrared camera 422, auxiliary recorder 424, environmental measurement thermocouple 425, and non-metal measurement thermocouple 428. The predetermined operating parameters may be stored in the storage 414 for future reference regarding the future state prediction of the refractory lining 434 and may be supplied to the computer complex 410 via the terminal 406 by user input or historical data previously processed by the processor 412.

[0150] The predetermined operating parameters may include, but are not limited to, historical data related to one or more refractories applied to one or more past refractory linings lining the inner surface of the outer wall of a past production vessel that handled non-metals, the initial chemical composition and origin of the refractory lining 434, the initial physical design of the refractory lining 434, the grade of non-metal desired to be produced during the operating cycle of the production vessel 416, the physical and chemical attributes and the amount thereof of the filling components or continuous supply mix components added to the production vessel 416 during the operating cycle to produce the desired grade of non-metal, and the chemical attributes and the amount thereof of the additives, colorants, or combustion gases added to the production vessel 416.

[0151] For the purposes of the present application, the physical design of the refractory lining 434 may include, but is not limited to, the structural details of the refractory lining 434, the shape of the refractory components in the refractory lining 434, the size of the refractory components in the refractory lining 434, and the combination of the refractory components in the refractory lining 434.

[0152] Additional measured operating parameters may include, but are not limited to, the temperature and duration schedules for preheating, heating up, or cooling when the manufacturing vessel 416 is preheated or heated up before an operating cycle or cooled after the cycle. Further measured operating parameters may include the cycle time defined by the cumulative duration of the operating cycle, or any other relevant measured operating parameters specified in a particular non-metal manufacturing operation.

[0153] Using the above data, the processor 412 can calculate the exposure effect that an operating cycle has on the refractory lining 434 of the manufacturing vessel 416 and predict the future state of the refractory lining 434 after one or more subsequent operating cycles. The exposure effect that an operating cycle has on the refractory lining 434 may be calculated by comparing the structural conditions of the refractory lining 434 before the operating cycle with the structural conditions of the refractory lining 434 after the operating cycle. Based on the calculated exposure effect, the future state of the refractory lining 434 after one or more subsequent operating cycles is predicted. In other words, the exposure effect of the first cycle can be used to predict the future state of the refractory lining 434 after the second cycle, the third cycle, etc. The processor 412 may refer to data from all of the data sources mentioned above, but is not limited thereto, and may also include other data sources not mentioned herein.

[0154] In one example, to supplement the prediction of the future state of the refractory lining 434, the temperature data collected from the outer view infrared camera 422 and the inner view infrared camera 403 is correlated with the structural conditions of the refractory lining 434 before, during, and after each operating cycle, thereby supplementing the calculation of the exposure effect of the refractory lining 434. This enables a more accurate prediction of the future state.

[0155] In another example, to supplement the prediction of the future state of the refractory lining 434, the calculation of the exposure effect of the refractory lining 434 may be supplemented by considering the operational impact of one or more of the aforementioned predetermined or measured operating parameters on the exposure effect of the operating cycle on the refractory lining 434 in correlation with the collected structural condition data.

[0156] As an example, historical data related to one or more refractories applied to one or more past refractory linings lined on the inner surface of the outer wall of a past manufacturing vessel for producing a non-metal can be used to establish a historical pattern of exposure effects. Such a historical pattern can complement the comparison of the structural state of the refractory lining 434 before and after the operating cycle of producing the non-metal and its correlation with the temperature data collected from the outer view infrared camera 422 and the inner view infrared camera 403. Such historical data may be accumulated in the storage 414 of the computer complex 410 after the calculation of the exposure effect so that the processor 412 can predict the future state of the subsequent refractory lining with higher accuracy after each successive operating cycle.

[0157] Regarding the use of measured operating parameters to assist in the calculation of the exposure effect, an environmental measurement thermocouple 425 may be provided to measure the environmental temperature inside the manufacturing vessel 416. A non-metal measurement thermocouple 428 may be provided to measure the temperature of the non-metal being processed inside the manufacturing vessel 416.

[0158] Furthermore, an auxiliary thermocouple 402 may be provided to measure the temperature of the production vessel 416 when the production vessel 416 is empty and preheated or heated up before being filled with a non-metal, or while the production vessel 416 is being cooled at the end of an operating cycle. The auxiliary thermocouple 402, the ambient measurement thermocouple 425, and the non-metal measurement thermocouple 428 can provide the measured temperatures to the calculation complex 410 for consideration by the processor 412 during the calculation of exposure effects according to the prediction of the future state of the refractory lining 434.

[0159] To monitor the duration of the cycle time, a recording mechanism such as the cycle time recording device 423 discussed herein may be used to measure the cumulative contact duration while the non-metal, coating, or a combination thereof is in contact with the refractory lining 434 during the operating cycle.

[0160] Furthermore, to monitor the duration of preheating, heating up, or cooling, a recording mechanism such as the auxiliary recording device 424 discussed herein may be used to control and record the duration and temperature of the heating up performed on the production vessel 416 before the operating cycle, or the cooling performed on the production vessel 416 at the end of the operating cycle. Specifically, the duration of heating up or cooling can be measured by the auxiliary recording device 424 from just a few hours to up to several days. The auxiliary recording device 424 can be incorporated into a gas preheating device together with an automatic gas shut-off device.

[0161] Before the laser scan of the refractory lining 434 by the laser scanner 420, an orientation laser 419 may be provided to scan the production vessel 416 to identify the physical orientation of the production vessel 416. The scan performed by the orientation laser 419 assists the laser scan of the refractory lining 434 by the laser scanner 420 and helps to improve its accuracy. The physical orientation of the production vessel 416 is related to the position of the production vessel 416 relative to the process or facility in which the production vessel 416 is being used. The orientation laser 419 provides the identified physical orientation of the production vessel 416 to the computing complex 410 for consideration by the processor 412 to determine the correct positioning of the production vessel 416 and to be used for the accurate calculation of the exposure effects according to the prediction of the future state of the refractory lining 434.

[0162] More specifically, the data from the orientation laser 419 may enable the processor 412 to calculate thickness measurements from the spatial measurements of the surface of the refractory lining 434. Such measurements cannot be derived unless the physical position and orientation of the production vessel 416 are estimated or not accurately known. The data from the orientation laser 419 may enable the processor 412 to accurately know the physical position and orientation of the production vessel 416.

[0163] Since the orientation laser 419 can be placed anywhere on the outer wall of the production vessel 416 that is directly visible, safe, and unobstructed, the orientation laser 419 will be positioned to scan the relevant refractory lining portion of the production vessel 416. It should be noted that the physical orientation determination by the orientation laser 419 can be supplemented through the data provided by the laser scanner 420 regarding the production vessel 416.

[0164] Next, referring to FIGS. 5 and 6, a method 600 for predicting the future state of the refractory lining 434 that is lined on the inner surface of the outer wall of the production vessel 416 and is exposed to the operating cycle while the refractory lining 434 is exposed to non - metal is described.

[0165] For the purposes of the description of method 600, "manufacturing vessel" may refer to a vessel such as manufacturing vessel 416 that is exposed to non-metals, and an environment for processing or manufacturing non-metals. Further, computing complex 410, including processor 412 and any other control units, enables control of all processes including, but not limited to, scanning, measuring, transferring material to or from manufacturing vessel 416, observing, collecting, determining, predicting, and contemplating.

[0166] In one example, manufacturing vessel 416 may first be scanned by orientation laser 419 to identify the physical orientation of manufacturing vessel 416 prior to any scan of refractory lining 434 by laser scanner 420. The physical orientation of manufacturing vessel 416 may be referenced by processor 412 during any further contemplation, determination, and prediction by processor 412 regarding manufacturing vessel 416.

[0167] Further, after the physical orientation scan and prior to any scan of refractory lining 434, the preheat temperature, heat-up temperature, and cool-down temperature, and the duration while manufacturing vessel 416 is preheated or heated up prior to the operating cycle or cooled down after the operating cycle, may be measured by auxiliary thermocouple 402 and recorded by auxiliary device 424. The temperature data and preheat duration respectively collected by auxiliary thermocouple 402 and auxiliary device 424 may be used by processor 412 as measurement parameters when considering the operational impact of the operating parameters regarding the high-temperature environment for manufacturing non-metals on the structural state of refractory lining 434 after it has been exposed thereto.

[0168] Further measurements of the operating parameters may be performed during the operating cycle, for example, but not limited to, measurement of the temperature of the non-metal in the production vessel 416 by the non-metal thermocouple 428, measurement of the temperature of the environment in the production vessel 416 by the environmental measurement thermocouple 425, and measurement of the cumulative contact duration while the non-metal and the environment are in contact with the refractory lining 434 during heating by the cycle time recording device 423. These will be described in detail below. The predetermined operating parameters as described above can be provided to the computing complex 410 when convenient. However, as described above and further described below, any predetermined operating parameters provided to the computing complex 410 will be considered by the processor 412 in calculating the exposure effect on the refractory lining 434.

[0169] After any additional preparation steps are completed and before the operating cycle, a laser scan of the refractory lining 434 of the production vessel 416 is performed (S601). The laser scan before the operating cycle can be executed by the laser scanner 420. The implementation of the laser scan before the operating cycle may include collecting data regarding the structural conditions of the refractory lining 434 before the operating cycle.

[0170] Next, the operating cycle is executed, during which the production vessel 416 is filled with a high-temperature environment for manufacturing the non-metal, and then filled with the non-metal manufactured in the high-temperature environment. After the operating cycle is completed, a laser scan of the refractory lining 434 of the production vessel 416 is performed again (S602). Similar to the implementation of the laser scan before the operating cycle, the implementation of the laser scan after the operating cycle can also be executed by the laser scanner 420. Furthermore, the implementation of the laser scan after the operating cycle can also include collecting data related to the structural state of the refractory lining 434 after the operating cycle.

[0171] After the pre-operation cycle laser scan and the post-operation cycle laser scan, the processor 412 calculates the exposure effect of the operation cycle on the refractory lining 434 (S603). The processor 412 can determine the exposure effect by comparing the collected pre-operation cycle structural condition data with the collected post-operation cycle structural condition data. After calculating the exposure effect of the operation cycle, the processor 412 predicts the future state of the refractory lining 434 after one or more subsequent operation cycles based on the calculated exposure effect of the operation cycle (S604).

[0172] This prediction provides extremely important information for determining whether the manufacturing container 416 can be reused using the refractory lining 434 or whether the refractory lining 43 needs to be replaced. This can avoid accidents that cause excessive structural damage to the manufacturing container 416, resulting in reduced downtime, improved efficiency, and cost savings.

[0173] As an example, during the operation cycle, one or more infrared scans may be performed on the outer surface of the outer wall of the manufacturing container 416 by the outer view infrared camera 422. Through this scan, the outer view infrared camera 422 can collect data regarding the temperature of the outer surface detected during the operation cycle respectively. This temperature data can be correlated with the collected structural state data to more accurately determine the effect of exposure and predict the future state. At the same time, the deteriorated part of the refractory lining 434 can be identified based on the calculated exposure effect.

[0174] In another embodiment, the calculation of the exposure effect correlates with the collected structural condition data and, optionally, in this particular embodiment, correlates with the temperature data collected from the infrared scan, and includes considering the operational impact exerted on the refractory lining 434 during the operation cycle by one or more of the measured or predetermined operating parameters.

[0175] The predetermined operating parameters include, but are not limited to, the following, which include the predetermined operating parameters described above in this specification: historical data regarding one or more refractories applied to one or more past refractory linings exposed to a high-temperature environment and non-metals, the initial chemical composition and origin of the refractory lining 434, the initial design of the refractory lining 434, the physical and chemical attributes and the amounts thereof of the filling components or continuously supplied mix components added to the production vessel 416 during the operating cycle, and the history of the production vessel 416 during the period in which the refractory lining 434 is lined inside.

[0176] The measured operating parameters include, but are not limited to, the following, which include the operating parameters described above in this specification: the temperature and temperature changes of preheating, heating up or cooling measured by the auxiliary thermocouple 402, the period during which changes in the production vessel 416 measured by the auxiliary thermocouple occur, measured by the auxiliary device 424, the temperature measurement value of the non-metal inside the production vessel 416 by the non-metal measurement thermocouple 428, the temperature measurement value of the environment inside the production vessel 416 by the environment measurement thermocouple 425, the temperature measurement value of the inner surface of the refractory lining 434 by the inner view infrared camera 403, the measured value of the cumulative contact duration during which the non-metal and the environment are in contact with the refractory lining 434 during the operating cycle by the cycle time recording device 423, the respective measured values of the pressure and gas type inside the production vessel 416 by the pressure sensor 407 and the gas sensor 409, the measurement of the thickness of the refractory lining 434 via a radar / tomography scan by the tomography sensor 411, and the measured value of the glass drawing speed calculated by the processor 412.

[0177] The specific embodiments of the present invention have been described above. It should be understood that these embodiments are described for illustrative purposes only, and that numerous changes and modifications can be made by those skilled in the art without departing from the spirit and scope of the present invention. It is intended that all such modifications and alterations be included in the present invention insofar as they fall within the scope of the claimed invention or its equivalents.

Claims

1. A measurement system for predicting the future state of a refractory lining that is lined on the inner surface of the outer wall of a manufacturing container and is exposed to an operating cycle, comprising: One or more laser scanners configured to perform one or more pre-operation laser scans of the refractory lining before the operating cycle to collect data on the pre-operation structural conditions, and to perform one or more post-operation laser scans of the refractory lining after the operating cycle to collect data on the post-operation structural conditions; A processor configured to calculate the exposure effect on the refractory lining of the operating cycle by comparing the collected pre-operation structural condition data with the collected post-operation structural condition data, and to predict the future state of the refractory lining after one or more subsequent operating cycles based on the calculated exposure effect of the operating cycle; Including, The processor is further configured to calculate the exposure effect in consideration of the operational influence exerted on the refractory lining during the operating cycle by one or more operating parameters in a correlation with the collected structural condition data; The operating parameters are One or more historical data on one or more refractories applied to one or more past refractory linings, The initial chemical composition and origin of the refractory lining, The initial physical design of the refractory lining, The physical and chemical properties and amounts of the filling components or continuous supply mix components added to the manufacturing container during the operating cycle, The history of the manufacturing container during the period when the refractory lining is lined on the inner surface of the outer wall of the manufacturing container, And including one or more predetermined operating parameters selected from the group consisting of A measurement system.

2. Further comprising one or more outer view infrared cameras configured to perform one or more infrared scans of the outer surface of the outer wall of the manufacturing container during the operating cycle to collect temperature data on the temperature of the outer surface during the operating cycle; The processor is further configured to calculate the exposure effect by correlating the collected temperature data of the outer surface with the collected structural condition data. The system according to claim 1, wherein the processor is further configured to map the collected temperature data to identify a deteriorated portion of the refractory lining.

3. The system according to claim 1, further comprising a supplementary thermocouple configured to measure a duration of preheating, temperature rise, or cooling while the production vessel is preheated or heated up before the operation cycle or while it is cooled after the operation cycle, wherein the duration of preheating, temperature rise, or cooling is one of the operation parameters.

4. The system according to claim 1, further comprising a cycle time recorder configured to measure a cumulative contact time during the operation cycle in which the refractory lining is exposed to a high-temperature environment, wherein the cumulative contact time is one of the operation parameters.

5. The system according to claim 1, further comprising one or more environmental measurement thermocouples configured to measure a temperature of the high-temperature environment inside the production vessel during the operation cycle, wherein the measured temperature of the high-temperature environment is one of the operation parameters.

6. The system according to claim 1, further comprising an orientation laser configured to scan the production vessel to identify a physical position and orientation of the production vessel before the operation cycle.

7. During the operation cycle, one or more tomographic sensors configured to perform one or more tomographic scans of the production vessel from an outer surface of the outer wall of the production vessel to collect tomographic data regarding one or more of a thickness of the refractory lining during the operation cycle, The system according to claim 1, wherein the processor is further configured to calculate the exposure effect by correlating the collected tomographic data with an operational impact of the collected structural condition data.

8. A method for predicting a future state of a refractory lining that lines an inner surface of an outer wall of a production vessel and is exposed to an operation cycle, comprising: Performing, before the operation cycle, one or more pre-operation laser scans of the refractory lining to collect data regarding structural conditions before the operation cycle; After the operation cycle, perform the post-operation laser scan of the refractory lining one or more times to collect data on the structural conditions of the refractory lining after the operation cycle, and By comparing the collected structural condition data before the operation cycle with the collected structural condition data after the operation cycle, calculate the exposure effect of the operation cycle on the refractory lining by a processor, and Based on the calculated exposure effect of the operation cycle, predict the future state of the refractory lining after one or more subsequent operation cycles by the processor, and including The calculation of the exposure effect further includes examining the operational influence exerted on the refractory lining during the operation cycle by one or more operating parameters in the correlation with the collected structural condition data, wherein the operating parameters are one or more historical data on one or more refractories applied to one or more past refractory linings, and the initial chemical composition and origin of the refractory lining, and the initial physical design of the refractory lining, and the physical and chemical attributes and the amount thereof of the filling component or the continuous supply mix component added to the manufacturing container during the operation cycle, and the history of the manufacturing container during the period when the refractory lining is lined on the inner surface of the outer wall of the manufacturing container A method comprising one or more predetermined operating parameters selected from the group consisting of.

9. During the operation cycle, further comprising performing an infrared scan of the outer surface of the outer wall of the manufacturing container one or more times to collect data on the temperature of the outer surface during the operation cycle, The calculation of the exposure effect further includes associating the collected temperature data of the outer surface with the collected structural condition data, and mapping the collected temperature data to identify the deteriorated portions of the refractory lining. The method according to claim 8.

10. The method according to claim 8, further comprising measuring the duration of preheating, heating up, or cooling while the manufacturing container is preheated or heated up before the operation cycle or cooled after the operation cycle, and the duration of preheating, heating up, or cooling is one of the operating parameters.

11. The method according to claim 8, further comprising measuring a cumulative contact time of the operation cycle during which the refractory lining is exposed to a high-temperature environment, wherein the cumulative contact time is one of the operation parameters.

12. The method according to claim 8, further comprising measuring a temperature of the high-temperature environment in the production vessel during the operation cycle, wherein the measured temperature of the high-temperature environment is one of the operation parameters.

13. During the operation cycle, further comprising performing one or more tomographic scans from the outer surface of the outer wall of the production vessel to collect tomographic data regarding one or more of the thickness of the refractory lining during the operation cycle, The method according to claim 8, wherein the calculation of the exposure effect further comprises correlating the collected tomographic data with the collected structural condition data.

14. A measurement system for predicting a future state of a refractory lining lined on an inner surface of an outer wall of a production vessel and exposed to an operation cycle, One or more laser scanners configured to collect data regarding the structural condition of the refractory lining before the operation cycle before the operation cycle and to collect data regarding the structural condition of the refractory lining after the operation cycle after the operation cycle, By comparing the collected structural condition data before the operation cycle with the collected structural condition data after the operation cycle, calculating an exposure effect on the refractory lining of the operation cycle, and predicting a future state of the refractory lining after one or more subsequent operation cycles based on the calculated exposure effect of the operation cycle. A processor configured as described above, Including, The processor is further configured to calculate the exposure effect in consideration of the operational influence exerted on the refractory lining during the operation cycle by one or more operation parameters in a correlation relationship with the collected structural condition data, The operation parameters are Historical data regarding one or more refractories applied to one or more past refractory linings, The initial chemical composition and origin of the refractory lining, The initial physical design of the refractory lining, The physical and chemical attributes and the amount thereof of the filling component or the continuously supplied mixed component added to the production vessel during the operation cycle, The history of the manufacturing vessel during the period when the refractory lining is lined on the inner surface of the outer wall of the manufacturing vessel, and including one or more predetermined operating parameters selected from the group consisting of a measurement system.

15. further comprising one or more outer view infrared cameras configured to collect temperature data regarding the outer surface of the outer wall during the operating cycle, the processor being further configured to calculate the exposure effect by correlating the collected temperature data of the outer surface with the collected structural condition data, and the processor being further configured to map the collected temperature data to identify deteriorated portions of the refractory lining, the system according to claim 14.

16. A measurement system for predicting the future state of a refractory lining lined on the inner surface of the outer wall of a manufacturing vessel and exposed to an operating cycle, comprising laser scanning means for collecting data regarding the structural conditions of the refractory lining before the operating cycle before the operating cycle and data regarding the structural conditions of the refractory lining after the operating cycle after the operating cycle, calculating an exposure effect of the operating cycle on the refractory lining by comparing the collected structural condition data before the operating cycle with the collected structural condition data after the operating cycle, and predicting the future state of the refractory lining after one or more subsequent operating cycles based on the calculated exposure effect of the operating cycle, for performing including the processing means being further configured to calculate the exposure effect in consideration of the operating influence exerted on the refractory lining by one or more operating parameters during the operating cycle in a correlation relationship with the collected structural condition data, the operating parameters are one or more historical data regarding one or more refractories applied to one or more past refractory linings, and the initial chemical composition and origin of the refractory lining, and the initial physical design of the refractory lining, and the physical and chemical attributes and amounts of the filling components or continuous supply mix components added to the manufacturing vessel during the operating cycle, The history of the production vessel during the period in which the refractory lining is lined on the inner surface of the outer wall of the production vessel, and one or more predetermined operating parameters selected from the group consisting of a measurement system.

17. A measurement system for predicting the future state of a refractory lining that is lined on the inner surface of the outer wall of a production vessel and exposed to an operating cycle, comprising means for collecting structure condition data regarding the structure conditions of the refractory lining before the operating cycle before the operating cycle and structure condition data regarding the structure conditions of the refractory lining after the operating cycle after the operating cycle; means for calculating the exposure effect on the refractory lining of the operating cycle by comparing the collected structure condition data before the operating cycle with the collected structure condition data after the operating cycle; means for predicting the future state of the refractory lining after one or more subsequent operating cycles based on the calculated exposure effect of the operating cycle; including the means for calculating the exposure effect on the refractory lining of the operating cycle is further configured to calculate the exposure effect in consideration of the operating effects exerted on the refractory lining during the operating cycle by one or more operating parameters in a correlation with the collected structure condition data; the operating parameters are history data regarding one or more refractories applied to one or more past refractory linings, and the initial chemical composition and origin of the refractory lining, and the initial physical design of the refractory lining, and the physical and chemical properties and amounts of the filling components or continuous supply mix components added to the production vessel during the operating cycle, and the history of the production vessel during the period in which the refractory lining is lined on the inner surface of the outer wall of the production vessel, and one or more predetermined operating parameters selected from the group consisting of a measurement system.

18. A method for predicting the future state of a refractory lining that is lined on the inner surface of the outer wall of a production vessel and exposed to an operating cycle, comprising collecting, before the operating cycle, structure condition data regarding the structure conditions of the refractory lining before the operating cycle and, after the operating cycle, structure condition data regarding the structure conditions of the refractory lining after the operating cycle, and By comparing the collected structural condition data before the operation cycle with the collected structural condition data after the operation cycle, the exposure effect of the operation cycle on the refractory lining is calculated by a processor, and Based on the calculated exposure effect of the operation cycle, the future state of the refractory lining after one or more subsequent operation cycles is predicted by the processor, and including The processor is further configured to calculate the exposure effect in consideration of the operational impact of one or more operating parameters on the refractory lining during the operation cycle in the correlation with the collected structural condition data, The operating parameters are Historical data on one or more refractories applied to one or more past refractory linings, and The initial chemical composition and origin of the refractory lining, and The initial physical design of the refractory lining, and The physical and chemical properties and amounts of the filling components or continuous supply mix components added to the production vessel during the operation cycle, and The history of the production vessel during the period when the refractory lining is lined on the inner surface of the outer wall of the production vessel A method comprising one or more predetermined operating parameters selected from the group consisting of

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